ESAB TAF 801 / TAF 1251 User manual

Service manual

0740 800 212 GB 20180120

Valid for: serial no. 935-, 126-xxx-xxxx

TAF801, TAF1251

TABLE OF CONTENTS

0740 800 212 © ESAB AB 2018

READ THIS FIRST.................................................................................... 4

INTRODUCTION....................................................................................... 5

TECHNICAL DATA ................................................................................... 6

WIRING DIAGRAM................................................................................... 8

Component description ......................................................................... 8

TAF 801.................................................................................................... 9

TAF 801.................................................................................................... 12

TAF 1251.................................................................................................. 15

TAF 1251.................................................................................................. 18

2AP3 Interference suppressor board ................................................... 21

2AP3 Component positions.................................................................. 21

20AP1 Control board.............................................................................. 21

20AP1:1 Power supply ......................................................................... 22

Voltage monitoring............................................................................. 22

DC supplies, +24V............................................................................. 23

DC supplies, +24V_A ........................................................................ 24

DC supplies, +12V_CAN ................................................................... 24

20AP1:2 Thermal protection................................................................. 24

20AP1:3 Shunt input ............................................................................ 25

20AP1:4 Synchronizing ........................................................................ 25

20AP1:5 Arc voltage............................................................................. 26

20AP1:6 Gate pulses ........................................................................... 26

20AP1:7 CAN bus ................................................................................ 26

CAN power supply............................................................................. 27

20AP1:8 Start / Stop / Weld on............................................................. 27

20AP1:9 Analogue control.................................................................... 28

20AP1:10 Optional I/O ......................................................................... 28

Digital inputs...................................................................................... 28

Digital outputs.................................................................................... 29

Analogue outputs .............................................................................. 29

20AP1:11 Processor and miscellaneous circuits.................................. 29

20AP1 Component positions................................................................ 31

FAULT CODES ......................................................................................... 32

Fault log................................................................................................... 32

Fault code description ........................................................................... 32

SERVICE INSTRUCTIONS....................................................................... 35

What is ESD? .......................................................................................... 35

Service aid .............................................................................................. 35

MAINTENANCE....................................................................................... 36

Checking diodes and thyristors ............................................................ 36

LOAD CHARACTERISTICS .................................................................... 38

TABLE OF CONTENTS

0740 800 212 © ESAB AB 2018

Output voltage ...................................................................................... 39

IN-SERVICE INSPECTION AND TESTING.............................................. 41

General requirements ............................................................................ 41

Periodic inspection and test.................................................................. 41

After repair, inspection and test ........................................................... 41

Visual inspection .................................................................................... 41

Electrical test .......................................................................................... 42

Functional test ........................................................................................ 44

Test report ............................................................................................... 46

SPARE PARTS ......................................................................................... 47

REVISION LOG ........................................................................................ 48

Rights reserved to alter specifications without notice.

READ THIS FIRST

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS AND

ACCESSORIES" chapter in this manual.

This manual contains details of design changes that have been made up to and including

September 2017.

The manual is valid for:

TAF 801 with serial no. 935-xxx-xxxx and 126-xxx-xxxx.

TAF 1251 with serial no. 935-xxx-xxxx and 126-xxx-xxxx.

Power sources with serial number 935-xxx-xxxx up to 935-040-xxxx can differ from this

manual. See Circuit board identity in chapter "Wiring Diagram".

The TAF 801 and TAF 1251 are designed and tested in accordance with international

and European standards IEC/EN 60974-1 and IEC/EN 60974-10.

On completion of service or repair work, it is the responsibility of the person(s)

performing the work to ensure that the product still complies with the requirements

of the above standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

INTRODUCTION

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INTRODUCTION

The square wave output power sources TAF 801 and TAF 1251 are designed for high

productivity mechanized submerged arc AC welding (SAW).

Design structure of the power source

The power sources are two-phase connected to the mains and the square wave output

welding current is generated by an inductor in a full wave thyristor bridge-rectifier. The power

sources are fan cooled and externally controlled by ESAB's process controller PEK via a

CAN-bus or with an I/O controller (PLC). They can also be analogue controlled by process

controller PE1. See separate instruction and service manuals for a detailed description of

each control panel.

A thermal cutout switch protects the power source from overload. An indication lamp (yellow)

on the front panel illuminates when the thermal switch has tripped. The switch resets

automatically when the temperature of the thyristor heat-sink has decreased to an

acceptable level.

The power sources are designed for single operation and for combination with LAF power

sources. The TAF power sources are also prepared for dual operation in so-called Scott

connection.

Block diagram of TAF 801 and TAF 1251. (The diagram shows TAF 1251.)

In TAF 801 inductor L1 and shunt RS1 have changed places.

TECHNICAL DATA

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TECHNICAL DATA

TAF 801

Mains connection 346/380/400/415/500 V±10%, 1~50 Hz

440/550 V±10%, 1~60 Hz

Primary current I

max

147 A

Permissible load at SAW AC / DC

100 % duty cycle 800 A / 44.0 V

Setting range 300 A/32.0 V - 800 A/44.0 V

No-load voltage (U

0

)

70 V

No-load power 214 W

Effiency at maximum current 84%

Power factor at maximum current 0.83

Apparent power at maximum current 50.7 kVA

Active power at maximum current 42.2 kW

Operating temperature -10 °C to +40 °C (+14 °F to +104 °F)

Weight 495.0 kg (1091.3 lb)

Dimensions l × w × h 774×598×1228 mm

(30.47×23.54×48.35 in.)

Insulation class transformer F

Enclosure class IP23

Application class

TAF 1251

Mains connection 346/400/415/500 V, 1~ 50 Hz

400/440/550 V, 1~ 60 Hz

Primary current I

max

249A

Permissible load at SAW AC / DC

100 % duty cycle 1250 A / 44 V

Setting range

100A/24V–1250A/44V

1)

,

400A/28V–1250A/44V

2)

No-load voltage (U

0

)

73 V

No-load power 210 W

1)

, 240W

2)

Efficiency 89%

1)

, 87%

2)

Power factor 0.74

1)

, 0.77

2)

Apparent power

86.2kVA

2)

Active power

64.9kW

2)

Weight 608 kg

Dimensions l × w × h 774 × 598 × 1228 mm

Insulation class transformer F

Enclosure class IP 23

TECHNICAL DATA

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1)

Serial number 935-xxx-xxxx

2)

Serial number 126-xxx-xxxx

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

WIRING DIAGRAM

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WIRING DIAGRAM

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

NOTE!

The wiring diagrams show the power sources connected for 400 V / 50 Hz, mains

voltage.

Component description

Component Description Remark

20AP1 Control board

2AP2 Insulation board (for XS4)

2AP3 Mains filter board

C1 - C4, C6 Capacitor Interference suppression capacitor

C5 Capacitor Power correcting capacitor

E01 Ferrite core

FU1 Circuit breaker 2 pole 16 A

FU2 Circuit breaker 20 A

FU3 Fuse 1.25 A, slow blow (anti-surge)

FU4 Fuse 1.25 A, slow blow (anti-surge)

FU5 Fuse 3.15 A, slow blow (anti-surge)

HL1 Indication lamp ON White

HL2 Indication lamp High temperature Yellow

KM1 Main contactor

KM2 Contactor

L1 Inductor

M1 Fan 230 V AC

QF Main switch ON/OFF

R1, R4 Resistor

RC1 - RC6 RC−filter

RS1 Shunt

ST1 Thermal switch

TC1 Auxiliary transformer

TC2 Sync. transformer 2x

TM1 Main transformer

THY1 - THY4 Thyristor 4x

WIRING DIAGRAM

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Component Description Remark

X1 Mains terminal block

XS1 - XS2 Welding current outlet

XS3 Socket (workpiece -) 1 pole

XS4 Sleeve socket 28 pole

XT2 - XT4 Terminal block

TAF 801

Valid for serial no. 935-xxx-xxxx.

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

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WIRING DIAGRAM

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WIRING DIAGRAM

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TAF 801

Valid for serial no. 126-xxx-xxxx.

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

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WIRING DIAGRAM

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WIRING DIAGRAM

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TAF 1251

Valid for serial no. 935-xxx-xxxx.

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

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WIRING DIAGRAM

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WIRING DIAGRAM

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TAF 1251

Valid for serial no. 126-xxx-xxxx.

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

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WIRING DIAGRAM

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